SBIR-STTR Award

PEI is proposing to design and develop a composite frame structure which will serve as the foundation and means for easy assembly and removal of either array sections, modules or individual vertical block staves (VBS). PEI will develop structural technologies for building and installing these large conformal arrays to the exterior hull. PEI technology will be expanded to allow conformal sonar arrays on other parts of the ship that will create new opportunities for use of bow and sail structure volumes while improving sonar sensor performance. PEI design will allow easy installation and removal of array sections during the Extended Dry-dock Selected Refit Availability (EDSRA) of a submarine. PEI design of this framework would facilitate the attachment and removal of array sections (modules and VBS) using interlocking features and fasteners. In addition, would also be modular so that the array size could be increased if required. Composite materials are inherently corrosion resistant and can also offer acoustic transparency so as to have minimal impact on sonar performance. Also, since framework and VBS back panels will be designed using composites, the contours/shapes can be complex and features can be integrated, reducing assembly costs.

Benefit:
The benefits from PEI approach intends that by developing a composite framework or foundation that would be mounted to the hull surface, it will facilitate the attachment and removal of array sections (modules and VBS) using interlocking features and fasteners. It would also be modular so that the array size could be increased if required. Further, the framework could include features for attachment of fairings to transition the LVA to the hull surface. This plate would serve a two-fold purpose: first, it would provide additional strength and stiffness to the compliant VBS material; and secondly, it would include features (tabs, integral fasteners) that would permit easy attachment and removal from the array framework. Composite materials are inherently corrosion resistant and can also offer acoustic transparency so as to have minimal impact on sonar performance. Also, since framework and VBS back panels will be designed using composites, the contours/shapes can be complex and features can be integrated, reducing assembly costs. The ability to combine multiple features to enhance strength and stiffness, to incorporate fasteners and reinforcement where needed, as well as ease of assembly, can significantly lower systems level costs as they relate to installation and maintenance.

Keywords:
Arrays, Arrays,, Composites, Sonar

PEI is proposing innovative design and development of advanced composite components that will extend part/system service life and reduce maintenance costs across the fleet. Corrosion has been identified as a primary cause of escalating preservation costs and premature service failure. Components designed and fabricated using advanced composite materials offer such advantages as: high strength and stiffness/weight ratio, corrosion resistance, manufacturing flexibility, environmental stability, and low signature. Through the development of new materials and additives, composite structures can also afford Fire, Smoke and Toxicity performance, resistance to high temperatures, and long-term durability and toughness. The Navy currently makes use of composites in many critical and demanding applications, specifically to address corrosion issues as well as for weight reduction. Lower weight structures provide for a more stable vessel, and offer opportunities to add on critical hardware that simply wasnt feasible at the current weight. This Phase II project proposal describes a development approach for composite components for Navy systems such as Outboard Electronic Canisters and propulsion components. The proposed activities will be primarily focused on the evaluation and selection of materials, the design and analyses of components, and specimen and sub-element testing.

Benefit:
PEI anticipates that the composite OBE and seal components will be the first of many products from this SBIR. These composite OBEs could be fielded as a change to the current submarine sonar system; and, commercial industry underwater sensors, particularly in the oil and gas industry. The mechanical seal components have direct application to benefit the U.S. Navy (such as DDG-51, LCS propulsion systems); U.S. Coast Guard, U.S. Army (Army has more boats than the Navy that could benefit); and, many other commercial customers. Clearly, there is a strong transition path ahead which will not only increase U.S. industrial base skills, but save millions of dollars spent today. By removing key propulsion system components from any galvanic, crevice or natural corrosion investigative discussions it would benefit the navy in terms of support time lost and cost expenditures while at the same time opening up the possibilities in propulsion and hull design.

Keywords:
Shafts, Canisters, surface combatants, Seals, Composites, Submarines, Light weight, Structures